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    7 views459 pages

    BMW 5series 1989 1995

    Uploaded by

    roberto

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
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    BMW. 5-Series General Data and Maintenance Engine Transmission Suspension, Steering and Brakes Body Body Equipment Electrical System Equipment and Accessories Electrical Wiring Diagrams Foreword... Warnings and Cautions. Incox o10 020 100 110 113 116 17 118 Camshaft Timing Belt 200 210 230 310 320 400 410 510 512 513 600 510 Bit 612 720 728 Fundamentals for the Do-ityourself Owner Maintenance Program Engine—General 119 Lubrication System Engine Removal and installation 120 _Igntion System—OME Cylinder Head Removal 121 Battery, Starter, Alternator and Installation 130 Fuel Injection OME Cylinder Head and Valvetrain 160 Fuel Tank and Fuel Pump Camshaft Timing Chain 170 Radiator and Cooling System 4180 Exhaust System Transmission—General 240. Automatic Transmission Clutch 250 Gearshif Linkage Manual Transmission 260 Driveshaft Suspension, Steering and 380 Rear Suspension Brakos—General 331. Final Drive Front Suspension 340 Brakes Steering and Whee! Alignment Body—Genoral 411 Doors Fenders, Engine Hood 412. Trunki, Tailgate Exterior Tim, Bumpers 515. Ceniral Locking Door Windows. 520. Seats Interior Trim 540 Sunroof Electrical System—General 620 Instruments Fuses and Relays 630 Exterior Lighting Wipers and Washers {840 Heating and Air Conditioning Switches and Electrical Accessories 650 Radio Seat Belts ‘Airbag System (SRS) ‘back of book Selected Books and Electronic Editions From Bentley Publishers Driving “The Unfit Adsatage Test Bent ISN ors dey osor comp Diving Forces The Grand is Racing Wort Gg inthe Mack the Thi nee [A Fench Kiss With Deaths Steve icQueer snd tre Making of Le Mans Mie Rewer SON Osea The Spend Ment A Journey Through ihe Wo of Mater agg 198092 Mido! Kove SONGS Colng Faster Mastering the Art of Rae Dawg Th St rer Rang Stal ionirestensea The Racing Diver, ha oon SB os762017 Sports Car and Compaiton Diving CE eer Engineering Maximum Boost Besignng Teng and Mean ocr ene Cog chsen eeaoncbe Douche nto nd Engine Nnegement Cnty i A so tar Ca Awdynamie esate paseo 7603005 Reference Fad ack astated Auomotive Beater Peta oasre a1 Audi ‘Audi TT Official Factory Repair Manual MY 200) Electronic Edition Au of America ISBN O-SS7EO758-2 ‘Aud AWUS1 Official Factory Repair Manual 19862100 Electronic Elton Bene Publishers ISBN 08376-0761-2 ‘Aud 80, 90 Coupe, Quattro Official Factory Repair Maral: 1988-1992 ‘at of America ISBN 8376-03684 BMW ‘Complete Roundel 1969-1988 '§ CD-ROM set 30 Years ofthe Magazine ‘of the BMW Car Club of Americ, Ine BMW Car Cab of America BBN ORS7ASE2 [BMW Series (£30) Service Manual: 1984-1990 3181, 325, 525ees), 32518) ‘and 3251 Convertible Bente Pushes ISBN 08376-0925-0 [BMW 3 Series (E36) Service Man 199241995, ISIC, 823i, 32547C, Sass. MB Bentley Pabishers ISBN 08976-0926-9 [BMW 3 Series (E46) Service Manual 1999-2001, 3230Ci, S25UCUsi, S2BUC, 3201/Cifi Sedan, Coupe, Convertible and Sport Wagon riley Pabst ISBN O-83760320-X UMW S-Series (28) Service Manual: 1952-1888 528e, 533,531, 5355 Beto Publishers SBN OAS760318-8 [BMW 5 Series (E31) Service Manual 1989-1095 525,530, 5351, 50, Including ‘Touring Bente Publishers ISBN OSS76-0319-6 BMW 7 Series (E52) Service Manual: 1996-1994, 7351, 75H, 740, 7401, 7501. Bentley Publishes ISBN 08376408285, BMW 23 Roadster Service Maral: 1996-1098, 4 and cylinder engines Bentley Publishers SBN O8S70828'5, smpanion™* [BMW Enthusiasts Ce BMW Car Chih of A [BMW 3 Series Enthus ‘Companion™™ Fry Wo ISBN O72 [BMW 6 Series Enthasiasts Companion'™ Fermi Won ISBN 0-8376-0149-5 Unbeatable BMW: Fighty Years of Engineering and Motorsport Success forma Maton ISBN 08376400068 Chevrolet Chevrolet by the Numbers 1985-1959: ‘The Essential Chevrolet Parts Reference Alan Coen SBN OS37E 8759 Chevrolet by the Numbers 1960-1966: The Essential Chevrolet Parts Reference Ala Cote ISBN 08976-09364 Corvette 427: Practical Restoration of ‘67 Roadster Dive Sherman ISBN O-837602181 CCorvote Fue Injection & Electronic Engine Management: 19822001 hares O, Prot, SA ISBN OS376.0861.9 Ford Ford Fuel Injection and Electronic Engine ‘Contra: 1988-1995 CGurits ©, Profs, SAE ISBN O376.0301-3, ‘The Official Ford Mustang 5.0 Techical Reference & Performance Handbook ws. Al Kishen ISBN O-8376-02106 3 Harley-Davidson Harley-Davidson Evolution V-1win ‘Owner's Bible™ Mowe Lidl ISBN 08976-01460 Honda Civie Duty: The Ultimate Guide tothe World's Most Popular Sport Compact Gar, the Honda Givi, Ala Paradise ISBN OS760215-7 Jeep Jeep Owner ie eet RaN Saareois Porsche Porsche 911 Carrera Service Manual: 1884-1989, Coupe, Targa and Cabriolet Bently Putisher ISBN 0.83760291-2 Porsche 11 SC Service Manta: P5163, Coupe Tag an Cable Bentley Pais ISBN 0897025 Saab ‘Saab 90016 Valve Official Service Manual: 1985-1983, ene Pulser SBN 0837609129 ‘Saab 9008 Valve Offical Service Manual: Rene Pubtishers SBN 0.8376 0310:2 Toyota Toya Track & Land Cruiser Owner's ible Ms Lael SBN 8 Volkswagen Bate forthe Bev The Sor ofthe Bate forthe Cant Vv Factory and the Car tat Became an eon Around Ue Clee Cod buiipen 6B carers \ellewagen Spor ening or Stet and Compton Jet, Cll, Service Mana 19802002 YoU Gosling, 1 TDI Dasel 280 VR iat Taro Baie Pairs BN 76.0889 eta, Gol, GT, Cabrio Service Manual "S935 ncuing Jeng and Cols Beng Petes TSN HES Passat Offical Factory Repal Manual {ive00 EletoneEaton Boney Puss BEN 0 TEOTS 9 Volvo ‘Volvo 240 Service Manual: 1983-1903 Bentley Pubtishers ISBN 08376-0285-8 [RB] BentieyPubtishers [AUTOMOTIVE BOOKS AND MANUALS. Bene Publishers has publish service ‘manvals and autocie books nce 190, Plage ere Bey Publishes Tt Mowat Combs 00424695 fora fee ey 0 ur ovale aay, Foreword ‘This BMW 5-Series Service Manual covers the 1989 through 1996 525i models, the 1989 through 1983 835i models, and the 1984 and 1996 530) and 540i models, and is speciiclly de- signed to cover only those modots built forsale inthe United States. [BMW and most accessories and parts sellers specializing in BMWs refer othe S-Series covered by this manual as the E34 model. The code “E34” is BMW's internal code forthe basic platform shared by all ofthe cars covered by this manual. Excop! forthe engine and afew other components, the models covered by this manual share many of same components such as suspension parts, ‘body panels, andthe interior pieces. When ordering parts, especially body parts, knowing the E34 ‘code may be helpful BMW also uses an internal code forthe various engines used in the £34 models. The engines used in the 525i models are either M20, M50, or MEOTU. The engine used in the 5351 is known as the M20. The engine used in the 530) and 5401 is known as the M&O. This information is primarily Used intemally by BMW, but may be holpfulf you have access to BMW technical information. For the BMW owner with basic mechanical skils, this manual gives dotaled maintenance and repair information. In addition, the BMV owner who has no intention of working on his or her own car vl find that owning and reading this manual will make it possible to be better informed and to iscuss repairs mare inteligently with a professional technician. This manval has been prepared from the repair information that BMW provides to is factory-trained technicians and has been de- veloped primarily withthe do-t-yoursolf BMW owner in mind. The aim throughout has been clarity ‘and understanding with practical functional descriptions, step-by-step procedures, and accurate specifications. ‘The BMW owner intending to do maintenance and repair should havea sot of tools including aset ‘of meric wrenches and sockets, screwdrivers, a torque wrench, and feeler gauges, since these ba- sic tools willbe used to do the majority of the maintenance and repair procedures described inthis ‘manual. This manual includes detailed information on these basic tools and other tips for the begin- ‘erin the fist section of the manual, ented Fundamentals for the Do-It-Yourself Owner. Forsome ‘ofthe repairs described inthis manual, BMW technicians use special tools. The text will note when ‘a repair requires these special tools and, where possible, wil recommend practical alternatives. vi We have endeavoured to ensure the highest degree of accuracy possible. When the vast aray of, data presented in the manual is taken into account, however, no claim to infaliilty can be made, We therefore cannot be responsible for the result of any erors that may have creptinto the text, The publisher encourages comments from the reads of this manual in regard to any errors and, also, ‘suggestions for improvement in the presentation of technical material, Thase communications have been and wil be carefully considered in the preparation of future printings of this and other ‘manuals. Please write to Robert Bentley, Inc., Cambridge, Massachusetis 02138. [BMW offers extensive warranties, especially on components of the fuel delivery and emissions ‘control systems. Therefore, before deciding to repair a BMW that may still be covered wholly or in Party any warranties issued by BMW of North America, consult your authorized BMW dealer. You ‘may find that he can make the repair ether free or at minimum cost. Regardless ofits age and whether or no its stil protected by warranty, your BMW is beth an ‘easy car to service and an easy car to gel serviced. Soif at any ime a repair is needed that you feel is too diffcut to do yourself, a trained BMW technician is ready to do the job for you. Each autho- ized BMW dealer service department has made a significant invastmant in servieo and diagnostic test equipment, specials tools, and BMW original pars. He is also the best source of the most up- to-date repair and service techniques, which includes factory taining and technical literature. Ser- vvcing your BMW through an authorized BNW dealer wil insure that your investment willbe protect- ‘ed while maintaining the highest dagree of service standards. Robert Bentley Please read these warnings and cautions before proceeding with maintenance and repair work. WARNING— '¢ Some repairs may be beyond your capably. you lack the kil, tools and equiomert, ora suitable workplace for any roce- clue deserted in tis manual, we suggest you leave such repairs to an authorized BMW dealer senice department, or other qual- fied shop. ‘© Donotre-use any fastoners that are wom or deformedtin normal use, Many fasteners are designed to be used only once and ‘become Unvelable and may fall wnen used a second time. This includes, but is not limited to, nuts, bolts, washers, seocking nuts or bolts, cis and cote pins. Always replace these fastn- ‘rs with new parts. ‘© Never work under a ited car unless it is soiy supported on stands designed forthe purpose. Do not support a car on cinder tocs, holo tes or other props that may erumible under contn- uous load, Never work under a car that Is supported solely by a Jack, Nover work under the ear while the engine i running, €@ If you are gong to work under a car on the ground, make sure that he grounds level. Block the wheels to keep tho car from rol ing, Disconnect the battery negative (-) terminal (Ground strap) to prevent others from starting the car wile you ae under ‘© Never run the engine unless the work arsa is well ventilated. (Carbon monoxide kl ‘© Fingor rings, bracelets and other jowely should be removed so that they cannot cause electrical shorts, get caught in running machinery, of be crushed by Reavy pars ‘© Tie long hale behind your head. Do not wear a necktie, a scart, loose clothing, oraneckiaco when you work near machine tools or running engines. it your hair, clothing, or jewelry were to get ‘caught inthe machinery, sever injury could result |© Do not attempt to work on your ar if you do not feel well. You increase the danger of injury to yoursl! and others it you are tred, Upset or have taken medication or any other substance that may keep you trom being fly alert. © liuminate your work area adequately but safely. Use a portable ‘alot ight for working inside or under the car. Make sure the bu is enclosed by a wire cage, The hot flament ofan accidentally bro- en bub can Ignite spied tuo or ol {© Cate draining fuel, ol oF brake fd in suitable containers. Do ‘ot use food or Beverage containers thal might mislead someone Into crnking from them. Store flammable uids away from fe haz- ards, Wipe up spills al once, but do nat store the oly rags, which ‘can ignite and burn spontaneously. ‘© Always observe good workshop practices. Wear goggles when ‘you operate machine tools or work with battery acid, Gloves oF ‘ther protective cothing shouldbe worn whenever the job requires ‘working with harmful substances, © Groases, lubricants and other automotive chemicals contain toxie substances, mary of which are absorbed direct through the skin, Read manufacture’ instustions and warnings carefuly. Use hand and eye protection. Avoid direct skin contac. ‘© Friction materials such as brake or clutch discs may contain ‘asbestos fibers. Do not create dust by grinding, sanding, or by ‘leaning wth compressed ar Avoid breathing asbestos fibers and ‘asbestos dust. Breatning asbestos can cause serious diseases ‘such as asbestosis or cancer, and may resutin death ‘© Disconnect the battery negative (-) terminal (Ground strap) ‘whenever you work onthe fuel systom or the elactical system. Do at smoko or work near heaters or othr fie hazards. Koop an approved fe extinguisher handy, © Batierios give off explosive hydrogen gas curing charging. Keep sparks, ightad matches and open fame away from the lop ofthe baller, If hydrogen gas escaping from the cap vents i ‘ignited, it wil Ignite gas trapped inthe cols and cause the battery ‘explode, 1@ Connect and disconnect battery cables, jumper cabes or bat ‘ery charger only with the igniton switched of to provent sparks. Dornot disconnect the battery while the engine is running ‘© Do not quick-charge the batlary {for boost staring) fr longer ‘han one minute. Wat a least one minute before boosting the bat tery @ second time, ¢¢ Dornot alow battery charging votageto exceed 10.5 vols. the battery begins producing gas or boing violent. reduce the charg Ing rata. Boosting a sulfated battery ata high charging rate can cause an explosion. {© The air-concitoning system is filed wih chemical retigerant, which is hazardous. The AC system should be serviced only by trained technicians using approved refrigerant recoverylrecying ‘equipment, rained in laid safety precautions, and familar with regulations governing the discharging and disposal of automotive chemical refngerants. {© Do not expose any par ofthe AIC systom to high temperatures ‘such as open flame, Exceesive heat wilincroase system pressure ‘and may cause the system to burt ‘© Some aerosol ire iflatos are highly tammable. Bo extremely ‘cautious when repaitng tre that may have been inflated using fan aerosol tre infator. Keep sparks, open flame or other sourcas Ct gniton away fom the te repair area late and deflate the tre at least four tmes before breaking the bead ftom the rim. Com pletely remove the tie rom the rm before attempting any repair. ‘© Some cars covered by this manual are equipped with a supple- mental restraint system (SAS), that automatically deploys an ‘airbag in the event of rental impact. The afoag is inated by an explosive device. Handled impropety or without adequate sale- ‘quards, it can be accidently activated and cause serous injury ‘© Oncars equipped with ant-lock bakes (ABS), the ABS modular ‘assembly is capable of “set-pressuring’ upto 210 bar (3045 ps). ‘Serious jury may result ifthe unit is not properly depressurized before servicing the system, continued on next page vil Please read these warnings and cautions before proceeding with maintenance and repair work. cAuTION— «© Ifyou lack the skis, tools and equipment, ora suitable work ‘shop for any procedure described inthis manual, we suggest you leave such fepais to an authorized BMW dealer or othr quatied shop. ‘© BMW is constanty improving its cars and sometimes these ‘changes, bth in pats and specications, are mad applicable to fcarlier models. Therefore, part number ited in this marual are for referenco only. Always chock with your authorized BLAW dealer parts department forthe latest information, ‘© Before staring a job, make certain that you have a the neces- ‘sary tools and parts on hand, ead al the Instructons thoroughly, {Jo not attempt shortcuts. Use tools appropriate to the work and use only replacemant parts meeting BMW epectiatons, Make- shit toos, paris and procedures will not make good repairs. ‘© Use pneumatic and elecirc tools ony to loosen threaded parts {and fasteners. Never use these tals to tighten fasteners, espe: Cialy on light alloy paris. Always use a torque wrench to lighten fasteners tothe tigniening torque specticaton listed. {© Be mindful of the environment and ecology. Betore you dain the crankcase, find out the proper way to dispose of the ol. Bo not Pour el onto the ground, down a drain, or ino a stream, pond or lake. Consult local ordinances that gover the disposal of wastes. ‘© On cars equippod with th antock brakes (ABS), the ABS con- ‘tol unt cannot withstand temperatures from a paini-crying booth (ora heat lamp in excess of 203°F (95°C) and should not be sub- jected fo temperatures in excess of 185°F (85°C) for more than two hours, vill ‘© Before doing any electrical welding on cars equiped with ABS, isconnect the battery negative (-) terminal (Ground strap) and ‘he ABS contro unit connector. (© On cars equipped with ant thet races, make sure you know ‘the correct radio activation cade betore disconnecting the batory ‘0 removing the radio. it te wrang code is entered ino te racko "when power i restored, that radlo may lock up and be rendered Inoperable, even ifthe correct code is then entered. ‘© Connect and disconnect a battery charger only withthe battery charger switched of {© Do not quick-charge the battery (for boost starting) for longor than one minute. Wait atleast one minuto bafore boosting the bat tery a second time. ‘© Sealed or maintenance tree" batteries shouldbe siow:chargad only, at an amperage rato that is approximately 10% of the bat tery’ ampere-hour (A) rating. {© Donct alow battery charging voltage to exceed 16.5 volts. tthe battery begins producing gas or boing olen, reduce the charg- ing rato, Boosting a sulfated battery ata high charging rate can cause an explosion FUNDAMENTALS FOR THE DO-IT-YOURSELF OWNER 010-1 010 FUNDAMENTALS FOR THE DO-IT-YOURSELF OWNER GENERAL. 010-1 HOW TO USE THIS MANUAL... 010-2 Warnings, Cautions and Notes 010-2 GETTING STARTED. 010-2 Satety 010-2 Litting the Car. 010-3 To raise car safely 0103 To work safely under car. 010-4 ADVICE FOR THE BEGINNER. .. 010-4 Planning Ahead 010-4 Cleaniiness 10-4 Non-reusable Fasteners 010-4 Tightoning Fasteners... 010-4 Gaskets and Seals 0105 Electrical Testing 0105 Wire Repairs 0106 BUYING PARTS 106 Genuine BMW Parts 0106 Non-retumable Parts ..... 0106 Information You Need To Know. 010-7, SERVICE. 107 TooLs . o10-7 Basic Tool Requirements 010-8 Jack Stands ......... 010-9 Oil Change Equipment oro-10 Torque Wrench 10-10 Foeler Gauges ot0-10 Volt-Ohm Meter (VOM) or Multimeter... 010-11 BMW Special Tools oto-t1 EMERGENCIES o10-11 Changing a Tire oto Car Will Not Start or0-12 Jump Starting . o10-12 To jump start car. 010-12 Overheating 010-13 Low Oil Pressure. 010-13 Brake Fluid Level 010-13 Check Engine Warning Light 010-13 Dim Lights 010-13 Towing 010-14 Spare Parts Kit 010-14 Tastes 4, General Bolt Tightening Torques in Nm (max. permissible) 010-5 GENERAL Although the BMW is a sophisticated and complex machine, basic maintenance can be accomplished by an interested own- fer with mechanical skis and the right information. Most of the preventive maintenance thats required inthe lifetime ofthe av- erage BMWs well within the capebiltes of the do-i-yourselfer. WARNING — Your common sense and good dgment are crucial 10 safe and suacesstul sevice werk. Read proce: ‘dures though betore staring them. Think about whether the condon of you car, your lve of me: ‘chanical ski, or your love! of reading comoreben: ‘sion might result or cantnute in sore way to a occurence that might cause you injury, damage WARNING — Do not use this manual unless you are familiar with base autamotive epar procedures and safe work shop practices. This manual iusirates the work shop procedures required for mest service work: it (sata substitute for ul and up-to-date information trom the vehicle manusactorer or for proper raining {a an automotive technician. Note that isnot poe Sie for us to antjpae allo the ways or conctons under which vehicles may be serviced orto prove ‘auons as 0 al ofthe possbe hazards Dat may result. your car or result in an unsafe rapa. you have {outs for hese or oer reasons about your asty to perform sale repair work on your ea have the work done at an authorized BNW dealer or other ‘uated shop. ‘This section of the manual is intended to help the beginner {get started. To begin with there isa discussion on How To Use This Manual. Tips on mechanic's skils and workshop practio- es that can help the beginner doa faster and more thorough job ‘can be found under Getting Started. The basic tools needed to do most ofthe procedures in this manual are found under Tools. The section onds with a quick reference guide toEmer- sgencies, including basic troubleshooting and information on how to gauge the seriousness ofa problem, GENERAL 010-2 FUNDAMENTALS FOR THE DO-IT-YOURSELF OWNER HowTo USE THIS MANUAL, ‘The manual is divided into nine sections: (0 GENERAL DATA AND MAINTENANCE 1 ENGINE 2 TRANSMISSION ‘3 SUSPENSION, STEERING AND BRAKES 4 BODY 5 BODY EQUIPMENT 6 ELECTRICAL SYSTEM 7 EQUIPMENT AND ACCESSORIES ELECTRICAL WIRING DIAGRAMS. 0 GENERAL DATA AND MAINTENANCE covers the rec- ‘ommended maintenance schedules and service procedures ‘needed to do BMW scheduled maintenance work. Also within this section isthe 010 Fundamentals for the Do-it-yourself ‘Owner section, which contains basic instructions, tips and helpful hints for do-it-yourself maintenance and repair ‘The next seven sections (1 through 7) are repair based and are furtner broken down into three digit repair groups. Each ma- jor section begins with a General repair group, ¢.9. 100 En- ‘gine—General. These "00" (double zero) groups are mostly

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